Dust Collection System Recommendations?
Hi,
I’m about to take the plunge and switch from a shopvac to a dust collection system (single-stage) for my basement shop. Two questions:
1. Does quality/brand matter much on dust collectors, or is price and CFM all that are important? Seems like such a simple device that maybe brand is not so important. Does noise vary much from brand to brand?
2. How much CFM is really needed to operate one machine at a time (table saw, 12″ planer, jointer, bandsaw, etc.)? Is it worth buying a bigger machine or are the smaller ones good enough?
Thanks!
Matt
Replies
Matt you should already know that bigger is better.
As for which machine is better I know there is a mag. that had reviews on several different smaller makes of DC's. I am away from home right now so I am unable to dig them up but here is the short of it. There is a big difference between the different brands. The smaller machines will handle just about anything that a home shop can produce. The only draw back is that a smaller machine is not big enough to run on a network of pipes. It pretty much needs to be right at the source of the dust in order to work effectively. This is a bit of a problem if you are doing a lot of work that needs a DC. You will have to move the machine form station to station and connect it to each different tool. A slightly larger machine can be made stationary and with pipes and gates used to direct the flow of saw dust to your DC. The price is not much different on the larger machines and is worth considering.
Scott C. Frankland
Was the Newfoundland Wood Worker soon to be the Nova Scotia Wood Worker.
Matt, I'm in the process of setting up a system myself. I did a lot of reading and looking around and one thing I found is that the numbers can be very confusing. Some people told me that cfm is the important number, others say cfm is meaningless and static pressure is what you're after. In the end, I bought the biggest collector I could afford and I'm building the rest of the system as the budget allows. One thing I know you should definitely look for is a system with good quality felt bags(one micron or less). Canvas bags that can't trap finer than 30 microns will actually make your shop more dangerous to work in.
Thanks for the info. Do any of the brands come standard with the low-micro bags? It looks like it is an add-on for most systems. What brand did you settle on?
Matt
I'm in Canada and bought one from King Industrial, which I believe is a Canadian company. It's pretty standard. Has a 2hp, 220v motor. I think it's rated at 1600 cfm. I paid $425 cdn. (approx. $280 us) for it. It did come with a 1 micron bag which made it a pretty good machine for the money. If you're at all close to the border, you should seriously consider buying in Canada. The exchange rate means you can buy a lot of machine with your Big American Dollars.
I also did what Larry did and bought a trash can cyclone lid. If you use your planer a lot, you will be forever emptying bags. I've seen the cartridge type filters (they look like a very big automotive air filter), but I don't know if they would be any better than a good bag type.
Like Larry, I'll be installing mine in a separate space, as they do make a lot of noise. Personally, I'm too lazy to spend a lot of time moving a small collector from machine to machine. I would probably end up not using it at all for most jobs. That's why I went for a bigger, stationary system.
Edited 1/7/2003 11:50:42 AM ET by JIMSPRAGUE
Edited 1/7/2003 11:52:02 AM ET by JIMSPRAGUE
Did you look into the Dustboys. If you did just curious what you thought
No, I never looked at Dustboy collectors. I've never seen them in any of the stores up here. I'm not sure they're available in Canada. Checked out the website and they do look sort of interesting though.
Well I just bought one. Haven't recieved it yet. I chose Dustboy for a few reasons. First, the size. I'm in my basement those single stage dual bag models just seemed too big. Second, with the 2 phase you don't need to hook up that cyclone attachment which you inevitably will with a single phase. not that thats a big deal, unless space is at a premium(which in my case it is). Third. Quality. I don't know for sure yet, but it was my gut feel that the quality of the Dustboy was a lot higher. IE, Leeson motor, cast aluminum housing and impellor, it's the quietest in it's class and the plastic 55 gal drum that it comes with holds an awful lot of debris. I'm a little nervous about the purchase because it's not a name I could get much feedback about. Bottom line, I've bought all of the common brands (Delta,Grizzly, etc.) and while good there quality has never blown me away so I've decided to take a shot on a smaller co. I hope I haven't shot myself in the foot.
Any thoughts
Leeson motor, small, quiet, 2 stage? I don't know what you paid for your Dustboy, but it sounds like a winner. Unfortunately, I've never seen up close, but it sure sounds good.
When you get the Dustboy set up how about giving us an update? I'm in the evaluation process now and would be interested in hearing how you like it.
thanks, Hugh
The Jet I was referring to earlier has the option for two 4" ports or one 6" port. I think this is fairly standard on the mid size to larger collectors. I assumed from the configuration that going to 6" was okay, and I also read on the "Bill's Cyclone Research" page that you needed at least 5" to 6" lines to get the desired CFM for most machines. I hope that I haven't made the wrong decision on my plumbing, because I opted for the expensive stuff. :)
Done. I'll keep you posted.
For a movable collector, Dustboy is on the pricey side, but well engineered. I looked into it and decided against it because you need to lift quite a bit of weight, both to dismount the blower and to empty a 55 gal drum. I've had surgery on my lower back once; that's enough for me. If the weight is not a problem, or you can rig a block and tackle or equivalent, the design fundamentals are much better than the traditional bag style, or even the new Jet, which is also more expensive than a standard 2-bag unit. Otherwise, the Oneida is the most intelligently designed of the collectors marketed to consumers, and built extremely well. There are other makes that mostly market to commercial customers, similar in design to the Dustboy, but they tend to be much more expensive. If cost or other issues dictates a bag style, PennState now sells collectors with bags that capture the problematic fine dust (particles between 2 and 5 microns). I think Bridgewood does as well. Jet and others make you throw away the original bags and replace them with felt bags purchased separately. Add the cost of the pre-separator, and a unit advertised at $250 costs more like $400.
Hi,
In addition to the felt small-particle bags, I'd look at the filtered dust collectors. Jet just came out with one (and a method of converting old dust collectors to this cleaner system)...I suspect other have them as well.
I have an 1100 CFM unit and am in the process of moving it to a location outside my main space...for noise and dust reasons.
I'll also purchase a trash-can-lid cyclone to try to get most of the material in trash cans vs. the dust collector bags...means less hassling with the dust collector bags, etc.
Good luck.
Let us know how things go!
lp
You need both static pressure (which is what makes the air move through restrictions like ducting and bags), and flow (CFM, which is what makes the dust move). Neither high static pressure with low flow (shop vac), nor high flow rate without static pressure (cheap box fan in free air - no flow restriction) will do it alone. Not coincidentally, shop vacs and box fans are relatively low power devices; it takes lots of power to move lots of air through lots of restriction. Look at the fan curves at the sites below. As static pressure increases, flow drops. You need enough flow at the machine, through all the ducting in use, to carry the dust and chips, and the air speed through the ducting must be high enough that nothing settles out on the way. Too large a duct, and the chips settle out. Too small, and the restriction is too much to yield good flow. Figure about half the CFM values stated by manufacturers will actually happen once you add some ducting and connect a machine. Taunton publishes a couple of excellent books on the subject. Lots of info is also at manufacturer's web sites.
http://www.pennstateind.com/Merchant2/merchant.mv?Screen=DUST&Store_Code=PSI&/#Anchor-Fan-49575
http://www.oneida-air.com/systems/1-2/1-2perfcurve.htm
Having said all that, I think that 1.5 hp is about the bare minimum size for small ducted systems, and more is always better. Smaller portable systems are OK if you use a single short hose to the machine, moving it from machine to machine as needed. I use 300-400 CFM for saws, and 600-800 CFM for chip makers like a planer or shaper. Others may think differently.
Be seeing you...
I recently purchased the Jet 1100 with the new cannister filter. So far I'm really happy with it. For the first couple weeks I just used a 4" flex hose and dragged it around to my various machines. I recently purchased 6" spiral galv pipe and y's with 4" laterals and blast gates to start setting up my plumbing. I started with about 15' of pipe and two y's and plan on sharing the two connections with four machines. I've got the system laying on the floor along a wall, and have it connected to my collector with a piece of 6" flex hose. It could be my imagination, but it feels to me like it is not pulling as hard from the end of my hose now as it was before. I was under the impression from things I read that going to a 6" trunk would increase my flow. Am I just feeling the loss in static pressure? And if so, is this okay?
Also, any comments on where to locate my trunk line? Overhead would be nicely out of the way, but then I'd have long 4" flex hose running to my machines and I'm worried about my collector not having the umph to pull the chips up. Maybe I'll just have to leave it on the floor.
Thanks for any help.
If I'm reading your description correctly, you still have 4" flex to the machine, but you've in essence inserted 6" flex, 6" rigid, elbows, y's, transitions, and blast gates into the air stream. What you're feeling is the reduction of flow rate due to the increase in flow restriction (more available static pressure used to overcome flow restriction, so flow decreases). Nothing can increase air flow above no hose or duct at all. Remember, everything adds restriction, and the smaller and/or more abrupt they are, the more restriction added compared to larger and/or less abrupt. A longish 4" flex may actually have less restriction than a short flex with larger hard duct and all those fittings. Take a look at this web site for an idea of how fast fittings and flex add up to equivalent pipe lengths. There are other sites, also. It may help to keep everything 6" until the blast gate and short flex, as long as the chips can still be carried. As I said before, 1.5 hp is about the bare minimum with a ducted system, IMO. And keeping everything on the floor is probably a good idea if it keeps runs to a bare minimum.
Edit: Oops! Forgot the link. http://www.airhand.com/design.html
Be seeing you...
Edited 1/8/2003 12:37:00 PM ET by TDKPE
Thanks for the information. I did some reading at "Bill's Cyclone Research Page":
http://cnets.net/~eclectic/woodworking/cyclone/
and thought that increasing to 6" from the machine instead of 4" would increase my air flow. I have 6" flex from the machine connected to 6" rigid trunk line. I have blast gates right at the y's connected to 4" flex that runs 5 to 10 feet to a tool. Is there a better way I should have set this up? My shop is small, in a basement with mobile tools, and basically all along one wall that is about 25 feet long. Most of my tools that need collection the worst are along a stretch that is only about 15 feet long. My trunk line, for example, is only along this section of wall.
Thanks again!
If you've gone from moving the DC to the machine, connected with 5' of 4" flex, to having 15' of 6" duct, some 6" flex, fittings, reducers, blast gates, and another 10' of 4" flex, you will certainly have less flow. But the real question is, is what you have now adequate? Flow loss is inevitable, but if what you have at the machine carries the dust and chips to your satisfaction, then you're golden. The installation is successful.
By the way, the static pressure is measured at the blower inlet (and compared to the blower outlet, technically), so as you add restriction the static pressure at the inlet increases while the flow decreases, as per the fan curve for that unit. You could easily measure this by drilling a small hole at the inlet and another at the outlet, inserting a tight-fitting nylon hose, one end into each hole, with a U-bend filled with water between. Start the unit, and measure the height difference between the two water surfaces. That's the "inches water gauge" they're referring to. You'll see it change as the blast gates are opened and closed, and decrease as you remove the 6" inlet hose. Removing the canister or outlet hose will further decrease the difference. The maximum static pressure would come from completely blocking the inlet. Look at the fan curves for typical blowers, and you can relate what you see to the obvious increase/decrease of flow in inverse proportion to static pressure. You probably won't get what the manufacturer claims. Just in case your interested. Be seeing you...
Don't know if this helps.
When I set up my Penn State Cyclone, it came with a 5" input.
I talked to one of the experts at Penn State and asked if it would
help to go to 6" pipe for all my runs.
He said I wouldn't improve things, and that I should stay with the
5" pipe for my runs.
I did that nad it works fine.
Jeff
But I wonder if using a 6" primary duct would not hurt even though the inlet to the dust collector is 5". I was planning on using a trashcan chip separator and they only have 4" inlets. (I bet I could fudge them to 5")
I'm buying one of those $119 DC from HF that is supposed to be 2 hp (bla bla bla)...
If this collector is a POS I'd at least like to have the right size duct installed for use with a "proper" DC. My longest 6" run will be about 26' with 3 L's.
This chit is gettin' complicated. :)The proof is in the puddin'
I can't beleive the $119.00 dust collector will have enough CFM to keep particle velocity over 4000fpm in a 6" duct. If the inlet to the dust collector is 5" there will be no gain by going to a 6" main trunk, all it will do is reduce velocity.Tom
You may find that some of the collected wood will remain in the 6"
pipe due to the slowing of air velocity.
Also you might have a catch area where the pipe changes size for
debri to collect.
Just some more food for thought.
Jeff
Some of the posts here are way off base and you should be careful. Increasing the pipe size will decrease air velocity and the dust/chips will not be carried efficiently to the collector. You must keep the velocity between 3500 and 4500 ft/s. Also, you cannot count on the advertized CFM from your dust collector. Most of these are rated in free air so that the number is really the capacity of the fan, not the system. Onieda and Air Handling systems have some really good info on their web sites explaining this. In general, 5" is the biggest trunk size you should use in a 1 to 2 hp system. These size collectors are good for only one machine at a time. The 5" pipe should run to the machine and be reduced to 4" at the machine. Think of static pressure as loss in the system. The collector itself usually accounts for 2 to 3" of static pressure. Generally in the 1 to 2 hp range, this leaves 4 to 5" of static pressure budget for the pipeing in your shop. The sites I have given you above have tables for various components and their associated pressure loss. I am certain that a 1.5 hp collector at 6.5" of static pressure will produce only about 300 to 400 cfm.
TDF
Tom,
I agree with most of what you have said, but could you check your velocity figures? "You must keep the velocity between 3500 and 4500 ft/s." Assuming that the notation "ft/s" means "feet per second," these figures equate to 2,386 mph and 3,068 mph respectively. These are high-supersonic speeds.
Thanks,
Dick Baker
Sunnyvale, CA
Sorry, your exactly correct it is Ft/Min.
TDF
Dick,
I used to work as an engineer associated with dust collection.
To carry dust, need minimum velocity of 12m/sec (approx 40ft/sec) in vertical ducts or 18m/sec (approx 60 ft/sec) in horizontal ducts. This means practically a minimum air velocity of 60ft/sec in the duct.
Hope this helps,
Eddie
edit: Didn't see Tom's reply until after I posted this. 40ft/sec = 2400fpm, 60ft/sec = 3600fpm.
Figures are industry standards
Edited 1/13/2003 5:32:36 AM ET by eddie (aust)
Matt -
I got the Delta 1200 CFM DC (50-850??). I start and stop mine maybe 30 times a day. As a result of that I had to get new starting and run capacitors for the motor after 2 years of use. Other than that, it's been a pretty good one. The capacitors that came with it were pretty sorry quality.
Mine sets outside so noise is not a factor. Also using the standard bags (25 micron??) that came with it because of it's setting outside. There will always be residual dust regardless of the type bag you get. Setting the unit outside minimizes that problem as well as the noise problem.
I have two 4" gates in the wall of the shop. One hose goes to my bandsaw and the other is shared between my rolling workbench (several outlets) and my planer. I only open one of those two gates at any one time. When the rolling workbench is hooked up, I only use one of those ports at any one time also. It has 4 ports. One of the two wall gates has a separator outside. That is just a 44 gallon trash barrel built so that the heavy stuff drops out of the air stream. That trash barrel sets outside beside the DC. Hardly any dust and only the larger chips falls into the barrel.
I use a large contractor size plastic bag on the bottom and the standard bag on top. The unit came with two bags and I alternate use of those. While one is on, the other is hung on a line outside and after a few days run through the washing machine. Using the plastic bag simplifies clean out. I just throw the bag away.
You want a balance between static pressure and volume for the size ports your using at any one time. A shop vac has high static pressure but low volume. The planer is the biggest volume chip maker and you want as much air volume as you can get there. When I run my planer all gates are blocked except for the 4" going to the planer. The pressure and volume are determined by the type and size fan used in the DC and the size and speed of the motor. Anything over 1.5hp should be on 220Volts. As far as I know, all DC motors run at a minimum of 3450 rpm.
If you can set yours outside, I think you would be very glad you did so.
PlaneWood by Mike_in_Katy
PlaneWood
One thing that isn't always mentioned is that all the chips pass through the impeller in a bag-type system. There's no problem if you only suck up chips. However, if you -- as most of us do -- expect the DC to also pick up floor sweepings, this design has a problem. Long shavings from hand planes can wrap around the impeller and choke it. Also, little peanut-sized cut-offs sound like shrapnel when they go through the impeller. To fix this, I added the usual trash-can drop-box out in front of the DC. Now the system eats more floor space, is clunky to move around, and I have to empty two things -- the can and the bag -- each time. Were I to do it over, I might well go to a cyclone system that removes most chips from the air stream before it gets to the impeller.
How about the Oneida systems? They advertise that if you send them dimensions and plans, they'll design a system for you. Has anyone gone through the process. Do they design a powerful enough system? Are there other companies that do better?
I've checked out their site and never heard anything negative about them except price. Trust me they'll design you a more than adequate system (they want to sell you the best ($) system they can).
I'm also looking into a 2-stage cyclone system. Donshop, in addition to the Oneida systems, I've been looking at the Blue Tornado Cyclone Dust Management systems as well. Blue Tornado offers DC layout help also. They seem very competitive in price/performance with the Oneida systems. I saw them at a WW show last year in VA. Their web site is: http://www.bluetornadocyclones.com/.
Does anyone know the advantage/disadvantage of the external bag filters versus the internal cartridge filters found on cyclone systems? Seems to me that the cartridge filters would be harder to clean and quicker to clog.
--Rob
Rob,
An advantage of an internal cartridge filter (e.g. Oneida 1.5 hp) is that it keeps the chips and dust from reaching the impeller. There are cases in which this is safer, such as when a metallic object is taken into the system. With bags, the debris hits the impeller first, then goes to the bags. On the other hand, with a trashcan-type "preseparator" attached to the inlet of a bag unit, any items that could pose a hazard upon impact with the impeller have probably dropped out.
Jim
I live where the climate varies between extremely hot and humid to colder than a popsickle. I've wondered how these extremes would affect a dust collector that was located outside. Would I need to keep it in a climate-contolled shed or something like that? I'm still in the planning stage and need some advice, since I really would prefer to locate the collector outside my shop if at all possible. What do you all know about this? Thanks.
If you can at all afford it, go with the Oneida. Saves on later upgrades.
Don't forget the plumbing can double the cost of a collector.
Paul
Matt
Just pruchased a Penn State 1 HP which with the 5" inlet turns 850 cfm. Comes with 5 micron Felt bags standard at $230. If you go to 1 micron FELT $249. Added a dust separator to it and put it all on a mobile base to move to each machine individually. The separator gets 90% of the chips and larger sawdust.
Did extensive shopping and this is IMO the best buy on the market if you are going to use on 1 machine at a time. Several mags have the PS as best buy. You get the cytclonic effect by adding the separator and all for under $300. If you think you want a piped stationary system latter, you would be better of to go with Penn State 1 1/2 HP or one of the other bigger machines> Problem with the others is you have to spend about $70 extra to get the 1 micron FELT bags. Quite a little catch. The new Jet filtered is around $400.
Will try to get a picture of the system soon. I haven't taken any yet for insurance purposes, but need to. As soon as I do, I will post.
Good Luck...
sarge..jt
Any company named Penn State must be good.....that will sell it to me on name alone.
Matt
PSU 1990
Matt
Up from the shop on coffee break. My wifes from the Altoona-Johnstown area of western PA. She was smart enough to marry a GA. boy. ha..ha..
If you are patient, I will try to have picture by the week-end. I'm building a 36' curved counter for my companies new 170,000 ft. facility. I hate deadlines, but I got one in this case.
Keep updated with your decision...
sarge..jt
Matt
Got some quickies this morning. Light was not great. Here's your Penn State DC with dust separator getting ready to take on about 200 linear feet of ripped sawdust. ha..
Luck with your decision...
sarge..jt
http://www.woodmagazine.com : has a forum dedicated to dust collection systems. They have a couple of extremely knowledgable fellows that can give you an answer to your questions. Also, they can direct you to various web-sites that show different hook-ups.
Roger
Matt,
I just purchased a Jet 1100 DC. I talked to alot of people and other responding to your question have stated the same. The dust collecter collects wood chips, air cleaners clean the dust from the air. I went ahead and bought the improved Jet air cleaner at the same time I purchased the dust collector. When I did that I qualified for a $100.00 rebate from Jet. I work in my garage and was going to install a ceiling fan to circulate the heat at the ceiling level. The cost for the ceiling fan was about $100.00 anyway, so the cost of the air cleaner with the rebate wasn't that bad. Now I'll be cleaning the air and circulating the heat at the same time.
There is a forum at http://www.woodmagazine.com that deals with dust colletors and patronized by some very knowledgable persons. You might also ask your question there regarding different mfgs.
Roger
I am shopping for a DC, and want to it right the first time. My bride says we are not moving. Am trying to compare Oneida and Woodsucker. Woodsucker says it's system is better and cheaper than Oneida's, and seems like a good product. Does anyone have the Woodsucker? Are there any opinions out there?
One of my issues is ceiling height, which is low, and a difficult ducting job given AC ducts, steam pipes, domestic water pipes, wires, etc. Also, two mid-house large chimneys cut the basement into 3 rooms, two of which I use for the shop. The air handler, laundry, boiler, hot water heater, and clutter live in the third. Both will fit, but not that comfortably. I would love to get some help on this decision.
s4s,
I don't know much about the woodsucker. I went with the Oneida 1.5HP and really like it. I sent them a diagram of my shop layout, both existing and proposed, and they did the design. I asked them to do the material list in stages of implementation which I indicated on the sketch. This was no problem. I also had some ideas for the design which they incorporated into the plan. Spent much time on the phone discussing options with them and this was no problem. In the end I have a design which I can follow and implement as I build my shop. I currently have the DC hooked up to three machines, TS, planer, and jointer. I have capped wyes where I will expand.
TDF
Thanks for the information. I am jealous of your high ceilings in the basement, and the uncluttered ceiling area as well. I have mega problems in this area, what with a house built in the Phila. area in about 1925 or so. The builder did not know that I would want to live in the basement, I guess.
The fellow at Woodsucker with whom I spoke, Larry (who is the owner), said that the testing, side by side, shows his machine has more umph. He said that Oneida went up to a 2 hp., but didn't change the fan blade, so that the hp. increase is of only very limited value. Theirs is a 12"; his a 13.3". He also told me that with their filter, I should get 35 to 40 bins of shavings before having to clean the filter. How is your ratio with the Oneida?
Larry offered design layout advice, which if I go with Woodsucker I will take him up on. Maybe I'll ask him for a local referral of a customer.
Thanks again.
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